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RANCANG BANGUN SISTEM PAHAT PUTAR AKTIF TERGERAK (ACTIVE DRIVEN ROTARY TOOL) UNTUK APLIKASI PEMBUBUTAN MATERIAL MAGNESIUM
Abstract Magnesium is an alkaline earth metal and including the third-most element in seawater. Because it has a mild nature, magnesium suitable used for a replacement to cast iron and steel in a heavy automotive components. Magnesium has a good characteristics in cutting and profitable. However besides the advantages that magnesium have, it’s also known as a metal that easy to burn especially when machining process with high speed and feeds number. The chip will be burn when the temperature higher than the temperature melting point of the material (4000C-6000C). While the driven rotary is activated, the cutting blade area get the cooling when the cutting blade area doesn’t touch the material during the process. Therefore, the cutting temperature will potentially decrease so that the ignition chip at magnesium machining will decrease and it’s causes the tool won’t easy to worn-out. The purpose of research is to design, build and test the system of active driven rotary tool for turning application of magnesium. The concept of design is to create a replacement tool post in lathe machine using active driven rotary tool. The rotary tool designed with propulsion system using the brushless DC motor, transmision system use gear and mandrel for gripping tool holder. Total dimensions of the machine designed is (158 x 150) mm. The highest run out of the test results 0.12 mm tool rotation used variation of 92.6 rpm to 2117 rpm, maximum vibration with velocity of 1.7 mm/s is still acceptable with ISO 2372 standard and feeding roughness parameters 0.05 mm and depth of cut 0.02 mm and also round workpieces 950 rpm resulted roughness of 2.46 μm. The result of roughness test is still in the tolerance limits of the ISO standard Roughness Number. Key word : magnesium, rotary tool, lathe, roughness, run out, vibration. Abstrak Magnesium merupakan logam alkali tanah dan termasuk unsur terlarut ketiga terbanyak pada air laut. Karena memiliki sifat yang ringan, magnesium cocok digunakan sebagai pengganti besi cor dan baja pada komponen otomotif yang relatif berat. Magnesium sebetulnya pada satu sisi dikenal karena karakteristik pemotongannya yang sangat baik dan menguntungkan. Namun dibalik kelebihan yang dimiliki, magnesium juga dikenal sebagai bahan logam yang mudah terbakar terutama pada saat pemesinan dengan kecepatan potong dan pemakanan yang tinggi. Geram akan terbakar ketika suhu pemotongan melebihi titik cair bahan yaitu (4000C - 600°C). Dengan menggunakan pahat putar, saat pahat berputar maka area pisau potong mendapatkan pendinginan saat pahat tidak melakukan proses pemotongan. Oleh sebab itu, suhu pemotongan pada pahat berpotensi menurun sehingga akan mengurangi penyalaan geram pada proses pemesinan magnesium dan pahat tidak mudah aus. Penelitian ini bertujuan untuk merancang, membangun serta menguji sistem pahat aktif untuk proses pemesinan magnesium. Perancangan yang dilakukan menghasilkan konsep penggantian tool post pada mesin bubut dengan menggunakan pahat putar. Pahat putar ini dirancang dengan sistem penggerak menggunakan motor brushless DC, sistem transmisi menggunakan roda gigi serta mandril untuk mencekam dudukan pahat. Dimensi total mesin yang dirancang yaitu (158 x 150 ) mm. Hasil pengujian run out tertinggi yang diperoleh yaitu 0,12 mm dengan variasi putaran pahat dari 92,6 rpm sampai 2117 rpm, getaran maksimum dengan velocity 1,7 mm/s masih tergolong acceptable sesuai standar ISO 2372 serta kekasaran dengan parameter feeding 0,05 mm, kedalaman potong 0,02 mm serta putaran benda kerja 950 rpm menghasilkan kekasaran sebesar 2,46 μm. Hasil pengujian kekasaran ini masih berada dalam batas toleransi dari standar ISO Roughness Number. Kata kunci: magnesium, pahat putar aktif, bubut, run out, kekasaran, getaran. Abstract Magnesium is an alkaline earth metal and including the third-most element in seawater. Because it has a mild nature, magnesium suitable used for a replacement to cast iron and steel in a heavy automotive components. Magnesium has a good characteristics in cutting and profitable. However besides the advantages that magnesium have, it’s also known as a metal that easy to burn especially when machining process with high speed and feeds number. The chip will be burn when the temperature higher than the temperature melting point of the material (4000C-6000C). While the driven rotary is activated, the cutting blade area get the cooling when the cutting blade area doesn’t touch the material during the process. Therefore, the cutting temperature will potentially decrease so that the ignition chip at magnesium machining will decrease and it’s causes the tool won’t easy to worn-out. The purpose of research is to design, build and test the system of active driven rotary tool for turning application of magnesium. The concept of design is to create a replacement tool post in lathe machine using active driven rotary tool. The rotary tool designed with propulsion system using the brushless DC motor, transmision system use gear and mandrel for gripping tool holder. Total dimensions of the machine designed is (158 x 150) mm. The highest run out of the test results 0.12 mm tool rotation used variation of 92.6 rpm to 2117 rpm, maximum vibration with velocity of 1.7 mm/s is still acceptable with ISO 2372 standard and feeding roughness parameters 0.05 mm and depth of cut 0.02 mm and also round workpieces 950 rpm resulted roughness of 2.46 μm. The result of roughness test is still in the tolerance limits of the ISO standard Roughness Number. Key word : magnesium, rotary tool, lathe, roughness, run out, vibration.
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